Compliant pin strip with integrated dam bar

Abstract

An improved compliant pin strip and process for making an electrical package having a printed circuit board encased in a housing and pin connectors mechanically and electrically connected to the printed circuit board and extending outwardly away from an outer surface of the housing is provided. This involves the use of a compliant pin strip having a dam bar that defines surfaces for a molding tool to close on and seal a mold cavity. The pin strip with dam bar enables a simplified, cost effective, and more robust manufacturing process.

1 . A process for fabricating an electrical package having a circuit board encased in a housing and pin connectors mechanically and electrically connected to the circuit board and extending through the housing and outwardly away from an outer surface of the housing, comprising:
 providing a compliant pin strip comprising a plurality of compliant pins that are held together in a spaced apart relationship, a compliant portion at one end of each pin, a dam bar comprising aligned members that extend between adjacent pins transversely of the length direction of the pins, the dam bar and pins defining surfaces for a molding tool to close on and seal a mold cavity;   inserting the compliant portion of each of the plurality of compliant pins and a corresponding compliant pin receiving hole in a printed circuit board to attach the compliant pin strip to the printed circuit board and thereby make an electrical connection between the printed circuit board and each of the compliant pins;   positioning the printed circuit board with the attached compliant pin strip on a molding tool and closing the molding tool so that the printed circuit board is contained within a mold cavity defined by the closed molding tool and so that surfaces of the molding tool close on surfaces of the dam bar and pins to seal around the dam bar;   introducing a moldable plastic material into the mold cavity; and   solidifying the moldable plastic material to form a housing for the printed circuit board with portions of the compliant pins projecting outwardly away from a surface of the housing.   
   
   
       2 . The process of  claim 1 , wherein the compliant pin strip includes a tie-down strip connecting ends of the pins opposite the compliant portion end of the pins. 
   
   
       3 . The process of  claim 1 , wherein the moldable plastic material is a thermoplastic. 
   
   
       4 . The process of  claim 1 , wherein the moldable plastic material is a thermosettable resin. 
   
   
       5 . The process of  claim 1 , wherein the pin strip is bent before introducing a moldable plastic material into the mold cavity. 
   
   
       6 . A compliant pin strip comprising:
 a plurality of compliant pins held together in a spaced apart relationship, each pin having a compliant end portion and an opposite distal end portion; and   a dam bar comprising aligned members that extend between adjacent compliant pins transversely of the length direction of the pins, the dam bar being located between opposite ends of the pins.   
   
   
       7 . The compliant pin strip of  claim 6 , further comprising pressure tabs adjacent the compliant end portions to provide bearing surfaces for applying pressure to insert the compliant portions into receiving holes of a printed circuit board. 
   
   
       8 . The compliant pin strip of  claim 7 , further comprising a tie-down strip connecting the distal end portions of the compliant pins.